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Yamaha F100D Service Manual

Yamaha F100D
249 pages
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LOWR
Lower unit
6-23
6D93G11
2. Align the alignment mark
a
on the bush-
ing with the alignment mark
b
on the
bracket.
3. Install the dowels
1
into the lower unit.
4. Install the lower unit into the upper case,
and then tighten the lower case mounting
bolts (nuts) to the specified torque.
È
X-transom model
5. Install the trim tab
2
to its original posi-
tion, and then connect the speedometer
hose
3
.
Shift rod push arm: 90890-06052
S6D81040
a
b
T
R
.
.
Lower case mounting bolt (nut):
39 N·m (3.9 kgf·m, 28.8 ft·lb)
S6D86180
2
3
LT
572
LT

Table of Contents

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Yamaha F100D Specifications

General IconGeneral
BrandYamaha
ModelF100D
CategoryOutboard Motor
LanguageEnglish

Summary

General information

How to use this manual

Guide for effective service using manual format and symbols.

Symbols

Explanation of symbols for data, lubricants, and sealants.

Safety while working

Procedures to prevent accidents, injury, and ensure quality service.

Identification

Information on applicable models, codes, and serial numbers.

Propeller selection

Guidance on choosing a propeller to optimize performance and engine life.

Predelivery checks

Essential checks for a smooth delivery process and efficient operation.

Specifications

General specifications

Detailed specifications including dimensions, weight, and performance for F80BET and F100DET models.

Maintenance specification

Specifications for engine components like power unit, cylinder head, and valves.

Tightening torques

Specified torque values for various parts and assemblies in N·m, kgf·m, and ft·lb.

Periodic checks and adjustments

Special service tools

Tools required for periodic maintenance and adjustments.

Maintenance interval chart

Guidelines for routine maintenance intervals based on operating hours and time.

Top cowling

Procedures for checking and adjusting the top cowling fit.

Fuel system

Checks for fuel hoses, joints, and fuel filters.

Power unit

Procedures for checking engine oil, timing belt, spark plugs, thermostat, and cooling passage.

Control system

Checks and adjustments for engine idle speed and throttle linkage.

Bracket unit

Checks for power trim and tilt operation and fluid level.

Lower unit

Procedures for checking and changing gear oil and inspecting the lower unit for air leakage.

General

Checks for anodes, battery, and lubrication points.

Fuel system

Special service tools

Tools specific to fuel system diagnostics and service.

Hose routing

Diagram showing the routing of fuel and blowby hoses.

Fuel filter and fuel pump

Procedures for checking, disassembling, and assembling the fuel filter and pump.

Intake manifold

Checks and installation of throttle position sensor and idle speed control.

Vapor separator

Procedures for reducing fuel pressure, measuring it, and disassembling/assembling the vapor separator.

Canister

Procedure for checking the canister for cracks and leaks.

Power unit

Special service tools

Tools for power unit maintenance, including compression and valve train checks.

Power unit

Checks for compression pressure, oil pressure, and valve clearance.

Throttle link

Information on the throttle linkage system.

ECM

Information on the Engine Control Module.

Junction box

Details about the junction box components.

Cylinder head

Procedures for removing, checking, and installing cylinder head components.

Exhaust cover

Procedures for removing, checking, and installing the exhaust cover and pressure control valve.

Cylinder block

Procedures for disassembling, checking, and assembling the cylinder block.

Lower unit

Special service tools

Tools required for servicing the lower unit components.

Lower unit

Procedures for removing, disassembling, and assembling the lower unit.

Propeller shaft housing

Procedures for removing, disassembling, and assembling the propeller shaft housing.

Drive shaft and lower case

Procedures for removing, disassembling, and assembling the drive shaft and lower case.

Shimming

Procedures for selecting and installing shims for pinion and forward gears.

Backlash

Procedure for measuring and adjusting forward gear backlash.

Bracket unit

Special service tools

Tools for servicing bracket unit components.

Shift rod

Exploded view and parts list for the shift rod assembly.

Bottom cowling

Exploded views and parts list for the bottom cowling components.

Upper case

Procedures for removing, disassembling, and assembling the upper case.

Steering arm

Procedures for removing and installing the steering arm.

Clamp brackets and swivel bracket

Procedures for removing, installing, and adjusting clamp brackets and trim sensor.

Power trim and tilt unit

Procedures for removing and installing the power trim and tilt unit.

Power trim and tilt motor

Procedures for disassembling, checking, and assembling the power trim and tilt motor.

Gear pump

Procedures for disassembling, checking, and assembling the gear pump.

Tilt cylinder and trim cylinder

Procedures for disassembling, checking, and assembling tilt and trim cylinders.

Power trim and tilt electrical system

Checks for fuses, relays, switches, and trim sensors.

Electrical systems

Special service tools

Tools for electrical system diagnostics.

Checking the electrical components

Procedures for measuring peak voltage and low resistance.

Electrical components

Views showing the location of electrical components.

Ignition and ignition control system

Checks for ignition spark, plug wires, coils, ECM, pulser coils, sensors, and relays.

Fuel control system

Checks for injectors, electric fuel pump, and relays.

Starting system

Checks for fuses and starter relay.

Starter motor

Procedures for disassembling, checking, and operating the starter motor.

Charging system

Checks for stator coil and rectifier regulator.

Troubleshooting

Special service tools

Tools for troubleshooting, including the Yamaha Diagnostic System.

Yamaha Diagnostic System

Introduction to the diagnostic system, its features, functions, and hardware requirements.

Power unit

Troubleshooting chart for engine not cranking or starting.

Bracket unit

Troubleshooting for power trim/tilt and shift mechanism issues.

Electrical systems

Troubleshooting for battery drain and charging system issues.

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